Gas component analysis system after ammonia synthesis heat exchange

Abstract

The invention relates to the technical field of ammonia synthesis, and particularly discloses a gas component analysis system after ammonia synthesis heat exchange, which comprises a sampling module, a remote sensing technology module, a gas analysis, data fusion and processing module, a real-time monitoring and feedback module and a safety and environment monitoring module, according to the invention, gas components are monitored in real time, and reaction conditions such as the flow ratio of nitrogen to hydrogen are adjusted in time, so that the generation rate of ammonia is remarkably increased; a high-precision automatic sampler and advanced analytical instruments such as a gas chromatograph and a mass spectrometer are adopted, so that high accuracy of collected and analyzed data is ensured, and a solid basis is provided for decision making; the system can monitor gas concentration changes in real time, find abnormal conditions such as gas leakage in time, guarantee operation safety, reduce potential risks, fuse and analyze multi-source data, realize dynamic optimization and improve the overall performance of the system; by optimizing reaction conditions, waste gas emission in the ammonia synthesis process is reduced, and the influence on the environment is reduced.

Description

Technical Field

[0001] The invention belongs to the technical field of ammonia synthesis, and in particular relates to a gas component analysis system after heat exchange in ammonia synthesis. Background Art

[0002] In the industrial process of ammonia synthesis, the gas composition analysis system after heat exchange plays a vital role, which is directly related to the production efficiency, resource utilization and environmental friendliness of ammonia. However, although the current technology has achieved the monitoring and analysis of gas components after heat exchange to a certain extent, there are still some shortcomings, which limit the further improvement of production efficiency and the comprehensive achievement of environmental protection goals.

[0003] Existing systems have limitations in accuracy and response speed in real-time monitoring of gas components. Traditional monitoring methods are often unable to quickly and accurately capture changes in trace components in gas components, especially in the high-temperature and high-pressure ammonia synthesis environment. These subtle changes are crucial to optimizing reaction conditions and improving ammonia production rates. In addition, the system has limited automatic adjustment capabilities for key parameters such as gas flow ratios, and often relies on manual intervention, making it difficult to achieve instant and accurate adjustments, which affects the maximization of production efficiency. At the same time, the low degree of automation in data collection and analysis is also a major bottleneck of existing technologies. Although some systems are equipped with automatic samplers and analytical instruments, they are still insufficient in data fusion, processing and intelligent analysis.

[0004] In view of this, the inventors proposed a gas component analysis system after heat exchange in ammonia synthesis to solve the above problems. Summary of the invention

[0005] The object of the present invention is to provide a gas component analysis system after heat exchange in ammonia synthesis to solve the problems raised in the above-mentioned background technology.

[0006] To achieve the above object, the present invention provides the following technical solutions:

[0007] A gas component analysis system after heat exchange for ammonia synthesis, comprising:

[0008] The sampling module uses an online sampler to collect gas samples in real time and removes moisture and impurities from the samples through a gas scrubber;

[0009] Remote sensing technology module, including remote sensing sensors and imaging systems, uses remote sensing sensors and optical remote sensing technology to detect gas types and concentrations through laser or infrared light sources, combined with high-resolution cameras to record the spatial distribution of gas components and analyze changes in gas concentration;

[0010] Gas analysis: pre-treat gas samples, use a condenser to condense the gas, use a filter to remove solid particles, use analytical instruments to obtain real-time gas data, and automatically optimize analysis parameters including gas flow rate, gas pressure and gas state according to real-time data changes to improve analysis efficiency;

[0011] Data fusion and processing module, which integrates data from remote sensing sensors, online samplers and analytical instruments, improves data accuracy and reliability through machine learning models, generates comprehensive reports, and provides more comprehensive gas composition analysis data;

[0012] Real-time monitoring and feedback module, based on gas component analysis data, calculates reaction rate, predicts the change trend of gas components, and guides production optimization;

[0013] The safety and environment monitoring module, combined with the sensor unit, monitors the environmental gases in the ammonia synthesis process in real time, including a gas leakage monitoring unit and an environmental impact assessment unit.

[0014] Preferably, the gas state of the gas sample is analyzed using the ideal gas state equation, which is expressed as:

[0015] PV=nRT

[0016] P: Gas pressure Pa in the reactor, affecting the reaction rate and gas volume;

[0017] V: Gas volume m 3 , refers to the effective volume of the reactor;

[0018] n: the number of moles of gas involved in the reaction, which affects the degree of reaction;

[0019] R: gas constant 8.314 J / (mol·K);

[0020] T: Gas temperature K, directly affects the reaction rate and gas behavior.

[0021] Preferably, the analytical instrument includes a gas chromatograph, a mass spectrometer and an infrared spectrometer;

[0022] Gas chromatograph GC: separation and quantification of major gas components;

[0023] Mass spectrometer MS: Highly sensitive analysis of the molecular structure of gases;

[0024] Infrared spectrometer FT IR: used for quantitative analysis of specific gas components.

[0025] Preferably, the separation efficiency of the gas chromatograph is calculated using the following expression:

[0026]

[0027] Where H: theoretical plate height of the chromatographic column, m, reflecting the separation performance;

[0028] L: length of the chromatographic column, m, affects the separation effect and analysis time;

[0029] N: Theoretical plate number, indicating the effectiveness and efficiency of separation.

[0030] Preferably, the data from the remote sensing sensor, the online sampler and the analytical instrument are integrated and weighted average calculation is adopted, and the expression is:

[0031]

[0032] in Weighted average, the fused gas concentration value, reflects the comprehensive results;

[0033] wi: weight of each measurement value, assigned according to measurement accuracy or reliability;

[0034] xi: Gas concentration values ​​measured by various sensors or instruments come from different measurement sources.

[0035] Preferably, the machine learning model is represented by a linear regression equation, which is expressed as follows:

[0036] y=mx+b

[0037] Where y: predicted gas concentration value, based on historical data;

[0038] m: rate of change, the rate at which gas concentration changes over time, reflecting the trend of change;

[0039] x: time, as an independent variable;

[0040] b: intercept, the starting value of the prediction model, indicating the initial state.

[0041] Preferably, the sensor unit includes a gas concentration sensor and an optical sensor;

[0042] Gas concentration sensor, which monitors the concentration of nitrogen, hydrogen and ammonia in the reactor in real time;

[0043] Optical sensors identify gas components through spectral characteristics and are used for gas composition analysis and detection of changes in the concentration of specific gases.

[0044] Preferably, the gas leakage monitoring unit monitors the leakage of ammonia and other gases in real time through a gas concentration sensor and an optical sensor;

[0045] The environmental impact assessment unit collects environmental data in real time through gas concentration sensors and optical sensors to assess the impact of the ammonia synthesis process on the environment.

[0046] Preferably, the reaction rate calculation expression for synthesizing ammonia is:

[0047] r=k·[A] m [B] n

[0048] Where r is the reaction rate, mol / (L·s), the amount of ammonia generated per unit time;

[0049] k: reaction rate constant, which depends on the reaction conditions, including temperature and catalyst;

[0050] [A]: Concentration of gas A involved in the reaction, mol / L, the main factor affecting the reaction rate;

[0051] [B]: Concentration of gas B involved in the reaction, mol / L, the main factor affecting the reaction rate;

[0052] m,n: Reaction order, reflecting the degree of dependence of the reaction on the concentration of each component.

[0053] Preferably, the gas types include hydrogen, nitrogen and ammonia.

[0054] Compared with the prior art, the present invention has the following beneficial effects:

[0055] (1) The present invention significantly improves the ammonia production rate by real-time monitoring of gas components and timely adjusting reaction conditions, such as the flow ratio of nitrogen and hydrogen. The use of high-precision automatic samplers and advanced analytical instruments, such as gas chromatographs and mass spectrometers, ensures the high accuracy of data collection and analysis, providing a solid basis for decision-making. The system can monitor changes in gas concentration in real time and promptly detect abnormal conditions, such as gas leakage, to ensure operational safety and reduce potential risks.

[0056] (2) The present invention integrates and analyzes multi-source data to achieve dynamic optimization and improve the overall performance of the system; by optimizing the reaction conditions, the exhaust gas emissions during the ammonia synthesis process are reduced, the impact on the environment is reduced, and the requirements of environmental protection regulations are met. Accurate gas component analysis helps to rationally allocate raw materials, reduce resource waste, and improve overall economic benefits. BRIEF DESCRIPTION OF THE DRAWINGS

[0057] Figure 1 This is a block diagram of a gas component analysis system after heat exchange for ammonia synthesis according to the present invention;

[0058] Figure 2 It is a block diagram of the sampling module of the present invention;

[0059] Figure 3 It is a block diagram of the remote sensing technology module of the present invention;

[0060] Figure 4 It is a block diagram of gas real-time data composition of the present invention;

[0061] Figure 5 It is a block diagram of the data fusion composition of the present invention;

[0062] Figure 6 This is a block diagram of the safety and environment monitoring module of the present invention. DETAILED DESCRIPTION

[0063] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0064] Embodiment 1:

[0065] See also Figures 1 to 6 As shown, a system for analyzing gas components after heat exchange for ammonia synthesis comprises:

[0066] The sampling module uses an online sampler to collect gas samples in real time and removes moisture and impurities from the samples through a gas scrubber to ensure accurate analysis;

[0067] Remote sensing technology module, including remote sensing sensors and imaging systems, uses remote sensing sensors and optical remote sensing technology to detect gas concentrations through laser or infrared light sources, monitors the distribution of hydrogen, nitrogen and ammonia in real time, and combines high-resolution cameras to record the spatial distribution of gas components and analyze changes in gas concentrations;

[0068] Gas analysis: pre-treat gas samples, use a condenser to condense the gas for subsequent analysis; use filters to remove solid particles and protect subsequent instruments; use analytical instruments, including gas chromatographs, mass spectrometers, and infrared spectrometers, to obtain real-time gas data, and automatically optimize analysis parameters, including gas flow rate, gas pressure, and gas state, according to real-time data changes to improve analysis efficiency;

[0069] Data fusion and processing module, which integrates data from remote sensing sensors, online samplers and analytical instruments, improves data accuracy and reliability through linear regression equation models, generates comprehensive reports, and provides more comprehensive gas composition analysis data;

[0070] Real-time monitoring and feedback module, based on gas component analysis data, calculates reaction rate, predicts the change trend of gas components, and guides production optimization;

[0071] The safety and environment monitoring module, combined with the sensor unit, monitors the environmental gases in the ammonia synthesis process in real time, including a gas leakage monitoring unit and an environmental impact assessment unit.

[0072] From the above, we can see that by real-time monitoring of gas components and timely adjustment of reaction conditions, such as the flow ratio of nitrogen and hydrogen, the ammonia generation rate can be significantly improved; the use of high-precision automatic samplers and advanced analytical instruments, such as gas chromatographs and mass spectrometers, ensures the high accuracy of data collection and analysis, providing a solid basis for decision-making; the system can monitor changes in gas concentration in real time, detect abnormal conditions such as gas leaks in a timely manner, ensure operational safety, and reduce potential risks.

[0073] Embodiment 2:

[0074] refer to Figures 1 to 6 As shown, for the gas state of the gas sample, the ideal gas state equation is used for analysis, and its expression is:

[0075] PV=nRT

[0076] P: Gas pressure Pa in the reactor, affecting the reaction rate and gas volume;

[0077] V: Gas volume m 3 , refers to the effective volume of the reactor;

[0078] n: the number of moles of gas involved in the reaction, which affects the degree of reaction;

[0079] R: gas constant 8.314 J / (mol·K);

[0080] T: Gas temperature K, directly affects the reaction rate and gas behavior;

[0081] The above formula is used to calculate the state of the gas, demonstrate the change process of the gas during the synthesis process, ensure the optimal conditions in the reactor, and thus increase the production of ammonia.

[0082] Specifically, the analytical instrument includes a gas chromatograph, a mass spectrometer and an infrared spectrometer;

[0083] The gas chromatograph GC is used to separate and quantify the main gas components;

[0084] The mass spectrometer MS: analyzes the molecular structure of the gas with high sensitivity;

[0085] The infrared spectrometer FTIR: is used for quantitative analysis of specific gas components.

[0086] Specifically, the separation efficiency of the gas chromatograph is calculated using the following expression:

[0087]

[0088] Where H: theoretical plate height of the chromatographic column, m, reflecting the separation performance;

[0089] L: length of the chromatographic column, m, affects the separation effect and analysis time;

[0090] N: Theoretical plate number, indicating the effectiveness and efficiency of separation;

[0091] The above formula helps evaluate the performance of the gas chromatography column and ensures that the gas components can be effectively separated to improve the accuracy of the analysis.

[0092] Specifically, the data from remote sensing sensors, online samplers and analytical instruments are integrated and weighted average calculation is adopted, and the expression is:

[0093]

[0094] in Weighted average, the fused gas concentration value, reflects the comprehensive results;

[0095] wi: weight of each measurement value, assigned according to measurement accuracy or reliability;

[0096] xi: Gas concentration values ​​measured by various sensors or instruments, coming from different measurement sources;

[0097] The multi-source data is fused through the weighted average method to improve the accuracy of the analysis results.

[0098] Specifically, the machine learning model is represented by a linear regression equation, which is expressed as follows:

[0099] y=mx+b

[0100] Where y: predicted gas concentration value, based on historical data;

[0101] m: rate of change, the rate at which gas concentration changes over time, reflecting the trend of change;

[0102] x: time, as an independent variable;

[0103] b: intercept, the starting value of the prediction model, indicating the initial state;

[0104] The above formula is used to establish a prediction model for gas concentration changes over time, which helps optimize production scheduling and improve process efficiency.

[0105] Specifically, the sensor unit includes a gas concentration sensor and an optical sensor;

[0106] The gas concentration sensor monitors the concentrations of nitrogen, hydrogen and ammonia in the reactor in real time;

[0107] The optical sensor identifies gas components through spectral characteristics, is used for gas component analysis, detects concentration changes of specific gases, and is suitable for multi-component analysis.

[0108] Specifically, the gas leakage monitoring unit monitors the leakage of ammonia and other gases in real time through a gas concentration sensor and an optical sensor to ensure safe operation;

[0109] The environmental impact assessment unit collects environmental data in real time through gas concentration sensors and optical sensors to assess the impact of the ammonia synthesis process on the environment.

[0110] Specifically, the reaction rate calculation expression for synthesizing ammonia is:

[0111] r=k·[A] m [B] n

[0112] Where r is the reaction rate, mol / (L·s), the amount of ammonia generated per unit time;

[0113] k: reaction rate constant, which depends on the reaction conditions, including temperature and catalyst;

[0114] [A]: Concentration of gas A involved in the reaction, mol / L, the main factor affecting the reaction rate;

[0115] [B]: Concentration of gas B involved in the reaction, mol / L, the main factor affecting the reaction rate;

[0116] m,n: reaction order, reflecting the dependence of the reaction on the concentration of each component;

[0117] Used to predict the rate of ammonia synthesis reaction, help optimize reaction conditions and increase yield.

[0118] Specifically, the gas types include hydrogen, nitrogen and ammonia.

[0119] From the above, we can see that by integrating and analyzing multi-source data, dynamic optimization can be achieved to improve the overall performance of the system; by optimizing the reaction conditions, the exhaust gas emissions in the ammonia synthesis process can be reduced, the impact on the environment can be reduced, and the requirements of environmental protection regulations can be met. Accurate analysis of gas components can help to rationally allocate raw materials, reduce resource waste, and improve overall economic benefits.

[0120] Embodiment three:

[0121] This design is specifically applied to the field of ammonia synthesis. In a large-scale synthetic ammonia plant, in order to improve the production efficiency and product quality of ammonia, while reducing energy consumption and environmental pollution, an advanced ammonia synthesis post-heat exchange gas component analysis system was introduced. The system integrates high-precision automatic samplers, gas chromatographs, mass spectrometers and other advanced analytical instruments, as well as intelligent data processing and monitoring software. By integrating advanced technologies such as high-precision monitoring, intelligent control and data analysis, it not only greatly improves the efficiency and safety of ammonia synthesis, but also opens up a new path for achieving a green and sustainable chemical production model.

[0122] Further, a gas component analysis system after heat exchange for ammonia synthesis:

[0123] System process overview:

[0124] Sampling: A high-precision automatic sampler collects gas samples from the ammonia synthesis reactor.

[0125] Pretreatment: The gas sample passes through a gas scrubber and condenser to remove impurities and moisture.

[0126] Remote sensing technology: Detect gas type and concentration through infrared light source, combine with high-resolution camera to record the spatial distribution of gas components and analyze changes in gas concentration.

[0127] Analysis: Gas composition analysis was performed using gas chromatography (GC) and mass spectrometry (MS).

[0128] Data fusion and processing: Fusion of analysis results with remote sensing data and historical data, and optimization using adaptive algorithms.

[0129] Real-time monitoring and feedback: Visualize changes in gas concentration through monitoring software and adjust reaction conditions based on the results.

[0130] Objective: To monitor gas composition in real time during ammonia synthesis reactions to improve ammonia production and safety.

[0131] Equipment: high-precision automatic sampler, multi-channel gas sampler, infrared light source generator, gas chromatograph, mass spectrometer, data fusion software.

[0132] Sampling process:

[0133] Sampling frequency: Sampling every 5 minutes for 1 hour.

[0134] Sampling points: reactor inlet, center and outlet.

[0135] Data collected

[0136]

[0137]

[0138] Data Analysis:

[0139] Trend analysis: Over time, the ammonia concentration increased from 0% to 15%, showing that the reaction was proceeding well, and the nitrogen concentration gradually decreased while the hydrogen concentration gradually increased, verifying the chemical dynamics of the reaction.

[0140] In addition, the infrared light source generator helps monitor and analyze the changes in gas composition during the ammonia synthesis process.

[0141] Optimization and adjustment:

[0142] Adjustment of reaction conditions: Based on real-time data, the flow ratio of hydrogen to nitrogen is adjusted to further increase the generation rate of ammonia.

[0143] Effect summary:

[0144] Data reliability: High-precision automatic sampler ensures the representativeness of data and provides a basis for optimization.

[0145] Improved reaction efficiency: Through data analysis and condition adjustment, the ammonia production rate was increased from the initial 0% to the final 15%.

[0146] Improved safety: The real-time monitoring system effectively reduces the risk of potential leakage and ensures safe operation.

[0147] As can be seen from the above, the above process demonstrates the complete flow of the gas component analysis system after heat exchange for ammonia synthesis, emphasizing the important role of high-precision automatic sampling and real-time data analysis in improving reaction efficiency and safety.

[0148] In the description of this specification, the description with reference to the terms "one embodiment", "some embodiments", "examples", "specific examples" or "some examples" etc. means that the specific features, structures, materials or characteristics described in conjunction with the embodiment or example are included in at least one embodiment or example of the present invention. In this specification, the schematic representations of the above terms do not necessarily refer to the same embodiment or example. Moreover, the specific features, structures, materials or characteristics described may be combined in any one or more embodiments or examples in a suitable manner. In addition, those skilled in the art may combine and combine different embodiments or examples described in this specification and the features of different embodiments or examples, unless they are contradictory.

[0149] In the drawings of the embodiments disclosed in the present invention, only the structures related to the embodiments disclosed in the present invention are involved, and other structures can refer to the general design. In the absence of conflict, the same embodiment and different embodiments of the present invention can be combined with each other.

[0150] Although embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions and variations may be made to the embodiments without departing from the principles and spirit of the present invention, and that the scope of the present invention is defined by the appended claims and their equivalents.

Claims

1. A gas component analysis system after heat exchange for ammonia synthesis, characterized in that: include: The sampling module uses an online sampler to collect gas samples in real time and removes moisture and impurities from the samples through a gas scrubber; Remote sensing technology module, including remote sensing sensors and imaging systems, uses remote sensing sensors and optical remote sensing technology to detect gas types and concentrations through laser or infrared light sources, combined with high-resolution cameras to record the spatial distribution of gas components and analyze changes in gas concentration; Gas analysis: pre-treat gas samples, use a condenser to condense the gas, use a filter to remove solid particles, use analytical instruments to obtain real-time gas data, and automatically optimize analysis parameters including gas flow rate, gas pressure and gas state according to real-time data changes to improve analysis efficiency; Data fusion and processing module, which integrates data from remote sensing sensors, online samplers and analytical instruments, improves data accuracy and reliability through machine learning models, generates comprehensive reports, and provides more comprehensive gas composition analysis data; Real-time monitoring and feedback module, based on gas component analysis data, calculates reaction rate, predicts the change trend of gas components, and guides production optimization; The safety and environment monitoring module, combined with the sensor unit, monitors the environmental gases in the ammonia synthesis process in real time, including a gas leakage monitoring unit and an environmental impact assessment unit.

2. The gas component analysis system after heat exchange for ammonia synthesis according to claim 1, characterized in that: For the gas state of the gas sample, the ideal gas state equation is used for analysis, and its expression is: PV=nRT P: Gas pressure Pa in the reactor, affecting the reaction rate and gas volume; V: Gas volume m 3 , refers to the effective volume of the reactor; n: The number of moles of gas involved in the reaction, mol. The number of moles of gas involved in the reaction affects the degree of the reaction; R: gas constant 8.314 J / (mol·K); T: Gas temperature K, directly affects the reaction rate and gas behavior.

3. The gas component analysis system after heat exchange for ammonia synthesis according to claim 1, characterized in that: The analytical instruments include a gas chromatograph, a mass spectrometer and an infrared spectrometer; The gas chromatograph GC is used to separate and quantify the main gas components; The mass spectrometer MS: analyzes the molecular structure of the gas with high sensitivity; The infrared spectrometer FTIR: is used for quantitative analysis of specific gas components.

4. The gas component analysis system after heat exchange for ammonia synthesis according to claim 3, characterized in that: The separation efficiency of the gas chromatograph is calculated using the following expression: Where H: theoretical plate height of the chromatographic column, m, reflecting the separation performance; L: length of the chromatographic column, m, affects the separation effect and analysis time; N: Theoretical plate number, indicating the effectiveness and efficiency of separation.

5. The gas component analysis system after heat exchange for ammonia synthesis according to claim 1, characterized in that: The data from remote sensing sensors, online samplers and analytical instruments are integrated and weighted average calculation is adopted, and the expression is: in Weighted average, the fused gas concentration value, reflects the comprehensive results; wi: weight of each measurement value, assigned according to measurement accuracy or reliability; xi: Gas concentration values ​​measured by various sensors or instruments come from different measurement sources.

6. The gas component analysis system after heat exchange for ammonia synthesis according to claim 1, characterized in that: The machine learning model is represented by a linear regression equation, which is expressed as follows: y=mx+b Where y: predicted gas concentration value, based on historical data; m: rate of change, the rate at which gas concentration changes over time, reflecting the trend of change; x: time, as an independent variable; b: intercept, the starting value of the prediction model, indicating the initial state.

7. The gas component analysis system after heat exchange for ammonia synthesis according to claim 1, characterized in that: The sensor unit includes a gas concentration sensor and an optical sensor; The gas concentration sensor monitors the concentrations of nitrogen, hydrogen and ammonia in the reactor in real time; The optical sensor identifies gas components through spectral characteristics and is used for gas component analysis to detect changes in the concentration of specific gases.

8. The gas component analysis system after heat exchange for ammonia synthesis according to claim 1, characterized in that: The gas leakage monitoring unit monitors the leakage of ammonia and other gases in real time through a gas concentration sensor and an optical sensor; The environmental impact assessment unit collects environmental data in real time through gas concentration sensors and optical sensors to assess the impact of the ammonia synthesis process on the environment.

9. The gas component analysis system after heat exchange for ammonia synthesis according to claim 1, characterized in that: The reaction rate calculation expression for synthetic ammonia is: r=k·[A] m ·[B] n Where r: reaction rate, mol / (L·s), the amount of ammonia generated per unit time; k: reaction rate constant, which depends on the reaction conditions, including temperature and catalyst; [A]: Concentration of gas A involved in the reaction, mol / L, the main factor affecting the reaction rate; [B]: Concentration of gas B involved in the reaction, mol / L, the main factor affecting the reaction rate; m,n: Reaction order, reflecting the degree of dependence of the reaction on the concentration of each component.

10. The gas component analysis system after heat exchange for ammonia synthesis according to claim 1, characterized in that: The gas types include hydrogen, nitrogen and ammonia.

Images